Vehicle battery assembly

ABSTRACT

A vehicle battery assembly having specialized fasteners that includes an integrated compression limiter. The compression limiter provides protection for the fastening joint of a cover and a tray of a housing for the battery assembly. The battery assembly may also include nut and bolt assembly which may be installed by a nut insertion tool. The nut insertion tool allows the nut and bolt assembly to be installed without damaging the tray or the cover.

CROSS REFERENCE TO RELATED APPLICATIONS

This U.S. patent application is a continuation of, and claims priorityunder 35 U.S.C. §120 from, U.S. patent application Ser. No. 16/814,659,filed on Mar. 10, 2020. The disclosure of this prior application isconsidered part of the disclosure of this application and is herebyincorporated by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates to various battery components related toa battery system for an electric vehicle. In particular, a cover for abattery of an electric vehicle and fastener systems associated with thecover.

SUMMARY

Typically, an electric vehicle includes a high voltage battery assemblyserving as the main power source for one or more propulsion motorsdriving the wheels of the vehicle. The battery assembly includes a coverin order to protect the battery cells from damage and the environment.The cover protects the high voltage battery from water by tightlysealing the battery. The cover may be made of plastic. Usually, coversare manufactured using injection molding or stampings. In thismanufacturing process, compression limiters for the covers may be builtinto the cover with minimal cost. In a vacuum formed cover, compressionlimiters may need to be manually pressed which adds cost and time forproducing the vehicle.

Fasteners in a vehicle assembly may also include nuts. These nuts mayneed to be inserted into deep and narrow channels, such as within thebattery assembly. Typically, nuts are inserted via hole in the bottom ofthe structure. This hole is vulnerable to water and may allow water toleak inside sealed assemblies.

The disclosed embodiments include fasteners with integrated compressionlimiters. This allows the manufacturing process to not require anadditional step of adding compression limiters.

Furthermore additional fasteners such as bolt and nut fasteners arepresent in assembly. A nut insertion tool may be provided in order toinsert nuts into narrow or tight channels within the vehicle structure,such as within the battery assembly.

DESCRIPTION OF THE DRAWINGS

The features, aspects, and advantages of the present disclosure willbecome apparent from the following description, and the accompanyingexemplary embodiments shown in the drawings, which are briefly describedbelow.

FIG. 1 is a vehicle with a battery assembly located within the vehicle.

FIG. 2 is an isometric view of the battery assembly for the vehicleshown in FIG. 1 .

FIG. 3 is a top view of the battery assembly for the vehicle shown inFIG. 2 .

FIG. 4 is a sectional view A-A of the battery assembly shown in FIG. 3 .

FIG. 5 is a side view of an exemplary fastener.

FIG. 6 is a side view of an exemplary battery assembly shown in FIG. 2without the cover.

FIG. 7 is a side sectional view of the battery assembly shown in FIG. 6.

FIG. 8 is a close up of a battery assembly with a nut insertion tool atlocation B of FIG. 7 .

FIG. 9 is a close up of the nut insertion tool being inserted to thebattery assembly.

FIG. 10 is an isometric view of the nut insertion tool.

FIG. 11 is an isometric view of the nut insertion tool according toanother embodiment.

FIG. 12 a shows a step in installing a nut into the assembly.

FIG. 12 b shows a step in installing a nut into the assembly.

FIG. 12 c shows a step in installing a nut into the assembly.

DETAILED DESCRIPTION

According to one disclosed embodiment of the disclosure, a batteryassembly for a vehicle is disclosed. The battery assembly includes ahousing. The housing includes a cover and a tray located under thecover, the cover including a first fastener hole. The tray including asecond fastener hole. A fastener configured to be inserted through thefirst and second openings to fasten the cover to the tray, wherein thefastener includes a head, a compression limiter, a body, and a thread.The body of the fastener is configured to be inserted to the secondfastener hole and wherein the thread is disposed outside of the body andis configured to engage the tray, and wherein the fastener is amonolithic structure.

According to another embodiment of the disclosure, a high voltagebattery assembly is disclosed. The high voltage battery is configured topower propulsive motors for a vehicle, the battery assembly comprising,a housing including a cover and a tray located under the cover,plurality of fasteners configured to fasten the cover to the tray alongthe perimeter of the battery assembly. Each fastener of said pluralityof fasteners includes a head with a slot, a compression limiter, a body,and a thread. The head of each fastener is configured to engage andprovide a first bearing surface configured to engage the cover. Thecompression limiter of each fastener provides a second bearing surfaceconfigured to engage the tray. Wherein each fastener is a monolithicstructure.

According to another embodiment of the disclosure, a fastener isdisclosed. The fastener comprising a head having a slot, wherein thehead is configured to engage a first layer, a compression limiterextending from the head opposite of the slot, a body. A portion of thebody includes a thread configured to be fastened to a second layerlocated under the first layer. Wherein the fastener is a monolithicstructure.

FIG. 1 illustrates a vehicle 1 comprising a high voltage battery (insidethe vehicle) that powers propulsive motors (not visible; inside thevehicle) that drives the wheels of the vehicle.

FIGS. 2 and 3 is a high voltage battery assembly 2 that includes ahousing 10. The housing 10 includes a cover 10 a and a tray (not shown;under cover 10 a) and are mated via a plurality of fasteners 12. Thehigh voltage battery may be mounted or integrated to the vehicle.Section A-A labeled is shown as FIG. 4 .

FIG. 4 is a sectional drawing showing the housing 10 with the cover 10 aand the tray 10 b. The first housing and second housing includesfastener holes 16 and 17 respectively. The fastener holes 16 and 17 areconfigured to be inserted with the fasteners 12. The fastener hole 16 ofthe cover 10 a is configured to overlap and be coaxially disposed tofastener hole 17 of the tray 10 b in order for fastener 12 to extendthrough. Each fastener 12 includes a head 13 and a stem portion. Thestem portion includes a compression limiter 14 a body portion. The bodyportion includes a non-threaded portion 15 a, and a threaded portion 15b. The head 13 of the fastener 12 may include a slot 18 shaped andconfigured to receive a tool for turning the fastener 12. A polygonalslot 18 is shown but different shapes may be provided for the fastenerhead. The head 13 may be larger than the rest of the fastener 12 inorder to keep the fastener from being driven further than the length ofthe fastener and in order to provide a bearing surface for the cover 10a. The body 15 a, 15 b of the fastener 12 is configured to extend intothe tray, and the threaded portion 15 b is configured to fasten to thetray 10 b via a threaded engagement. The length of the compressionlimiter 14 may be approximately equal to the thickness of the cover atthe adjacent area of the fastener hole 17. The cover and the tray mayinclude a plurality of fastener holes 16 and 17 each configured toreceive a fastener 12 as shown in FIG. 4 .

The primary function of the compression limiter 14 is to provide andmaintain joint integrity of connected components. The compressionlimiter 14 is designed to protect the components of an assembly (e.g.tray 10 b and cover 10 a of the battery assembly) from the compressiveloads generated by the tightening of the bolts, thereby assuringintegrity of the bolted connection. The compression limiter 14 providesa bearing surface for the tray 10 b. The compression limiter 14strengthens the housing 10 by withstanding the compressive force that isapplied when the fastener is tightened. The integrity of the housing 10is not compromised by the load that is applied. Each fastener hole 16 ofthe cover 10 a may include a raised lip 11 located at the opening ofeach fastener hole 16. The raised lip 11 may be disposed higher than theadjacent surface and is configured to be the bearing surface of thefasteners 12. The length of the compression limiter 14 may beapproximately equal to or slightly less than the thickness of the cover10 a including the thickness of the raised lip 11. The radius of theraised lip may extend approximately equal to the maximum radius of thefastener head 13 or slightly past the maximum radius of the fastenerhead in order to accommodate for the bearing surface of the fastener.

FIG. 5 shows an isolated fastener 12. The body 15 a of the fastener 12may be smaller than the outer diameter of the thread 15 b. The fastener12 may be of one piece or a monolithic structure.

FIG. 6 shows the battery assembly 2 with cover 10 a removed. The batteryassembly includes a plurality of battery modules 19.

FIG. 7 shows the battery assembly 2 with the cover 10 a removed. Abattery module 19 may be disposed on top of the tray 10 b. Each batterymodule may include one or more battery cells 19 a. The battery assembly2 may include one or more battery modules 19, but for clarity FIG. 6only shows a single module 19. A fastener (not shown) may be provided tofasten the battery module 19 to the tray 10 b. Encircled portion B isshown in FIG. 7 .

As shown on FIGS. 8 and 9 a nut insertion tool 20 may be utilized forthe assembly as an alternative for installing fasteners (e.g. nuts)without leaving holes on the assembly 2 (i.e. no openings required atthe bottom of the tray). A nut 21 is configured to sit on the nutinsertion tool 20 and is configured to receive a bolt 32 from above. Atunnel 30 is located on the underside the battery module 19 and isconfigured to receive nut(s) 21 and the nut insertion tool 20. The nutinsertion tool may have a width less than the width as the tunnel 30 soas to be configured to be inserted to the tunnel to install the nuts tocorresponding fastening holes 31 of the battery module 19. A bolt trench33 may be disposed on the tray 10 b below the fastening holes 31 inorder to accommodate the extension of the bolt through the nut.

FIG. 10 shows an isolated nut insertion tool 20 with nuts 21 disposed onslots 22 of the insertion tool 20. The slots 22 accommodate the shape ofthe nut 21. Rail 23 extends along the length of the insertion tool 20,and slots 22 are disposed within the rail 23. The rail is configured tohold the nut(s) 21 in place when the bolt 32 is inserted and tightenedfrom above the nut(s) 21. The thickness of the rail 23 is reduced at theslot locations in order to accommodate for the nut. The dimensions ofthe insertion tool and slot may also be vary depending on the nutrequired to be installed to the system. Multiple slots 22 may bedisposed along the rail, corresponding to different fastening pointsunder the battery module 2. The number of slots may correspond to anumber of fastening points of the battery module 2 along a line. Theshape of the slot and nut may be a rectangular or square shape, however,other polygonal slot shape may be utilized to accommodate different nutshapes. FIG. 11 shows another embodiment of the nut insertion tool 20with a stopper 24 configured to prevent the nut insertion tool frombeing inserted too far into the tunnel 30.

FIG. 12 a-12 c shows various stages of the installation process for anut 21 within the tunnel 30 utilizing nut insertion tool 20. Before thenut insertion tool 20 is inserted to the tunnel 30, nut 21 is insertedto a slot 22 as shown in FIGS. 9 and 10 . Multiple nuts 21 may beinserted to the tool 20 for each corresponding slot 22. Each slot mayinclude a magnet (not shown) in order to keep the nuts within the slot.The magnet may be fastened onto the nut insertion tool 20 via anadhesive or may be included integrally into the tool 20. The tool 20 maybe pushed into the tunnel such that the stopper 24 may be configured toalign corresponding slot(s) 22 to the corresponding fastening hole(s)31. After the nut 21/slot 22 has been aligned to the fastening hole 31,the bolt 32 is inserted to through the fastening hole 21 and may bescrewed into the nut 21. As the bolt 32 is rotated into the nut, thebolt 32 will lift the nut. The rail 23 will prevent the nut fromrotating. The height of the rail 23 may vary depending on the height ofthe tunnel. The height of the rail 23 will allow the nut 21 and bolt 32to be tightened to the required tolerance of the assembly. Once the nut20 and bolt 32 is tightened to the desired tolerance the tool may beremoved and be placed in a different tunnel for other nut and boltassemblies.

As utilized herein, the terms “approximately,” “about,” “substantially”,and similar terms are intended to have a broad meaning in harmony withthe common and accepted usage by those of ordinary skill in the art towhich the subject matter of this disclosure pertains. It should beunderstood by those of skill in the art who review this disclosure thatthese terms are intended to allow a description of certain featuresdescribed and claimed without restricting the scope of these features tothe precise numerical ranges provided. Accordingly, these terms shouldbe interpreted as indicating that insubstantial or inconsequentialmodifications or alterations of the subject matter described and claimedare considered to be within the scope of the disclosure as recited inthe appended claims.

It should be noted that the term “exemplary” as used herein to describevarious embodiments is intended to indicate that such embodiments arepossible examples, representations, and/or illustrations of possibleembodiments (and such term is not intended to connote that suchembodiments are necessarily extraordinary or superlative examples).

The terms “coupled,” “connected,” and the like as used herein mean thejoining of two members directly or indirectly to one another. Suchjoining may be stationary (e.g., permanent) or moveable (e.g., removableor releasable). Such joining may be achieved with the two members or thetwo members and any additional intermediate members being integrallyformed as a single unitary body with one another or with the two membersor the two members and any additional intermediate members beingattached to one another.

References herein to the positions of elements (e.g., “top,” “bottom,”“above,” “below,” etc.) are merely used to describe the orientation ofvarious elements in the FIGURES. It should be noted that the orientationof various elements may differ according to other exemplary embodiments,and that such variations are intended to be encompassed by the presentdisclosure.

It is important to note that the construction and arrangement of thebattery assembly and fasteners as shown in the various exemplaryembodiments is illustrative only. Although only a few embodiments havebeen described in detail in this disclosure, those skilled in the artwho review this disclosure will readily appreciate that manymodifications are possible (e.g., variations in sizes, dimensions,structures, shapes and proportions of the various elements, values ofparameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter described herein. Forexample, elements shown as integrally formed may be constructed ofmultiple parts or elements, the position of elements may be reversed orotherwise varied, and the nature or number of discrete elements orpositions may be altered or varied. The order or sequence of any processor method steps may be varied or re-sequenced according to alternativeembodiments. Other substitutions, modifications, changes and omissionsmay also be made in the design, operating conditions and arrangement ofthe various exemplary embodiments without departing from the scope ofthe present disclosure.

What is claimed is:
 1. A battery assembly comprising: a battery module;a cover comprising a first fastener hole; a tray comprising a topsurface supporting the battery module and a bottom surface disposed onan opposite side of the tray than the top surface, the tray comprising asecond fastener hole; and a fastener configured to be inserted throughthe first fastener hole and into the second fastener hole to fasten thecover to the tray and enclose the battery module between the cover andthe tray, the fastener comprising: a compression limiter having a lengththat is substantially equal to a thickness of the cover; and a bodyhaving a length that, when the fastener is inserted through the firstfastener hole and into the second fastener hole to fasten the cover tothe tray, extends from the top surface of the tray to the bottom surfaceof the tray.
 2. The battery assembly of claim 1, wherein, when thefastener is inserted through the first fastener hole and into the secondfastener hole to fasten the cover to the tray, a bearing surface of thecompression limiter abuts the top surface of the tray.
 3. The batteryassembly of claim 1, wherein: the fastener further comprises a head; andthe compression limiter is disposed immediately adjacent to the head. 4.The battery assembly of claim 3, wherein, when the fastener is insertedthrough the first fastener hole and into the second fastener hole tofasten the cover to the tray, a bearing surface of the head abuts a topsurface of the cover.
 5. The battery assembly of claim 4, wherein: thecover includes a raised lip disposed adjacent an opening of the firstfastener hole, the raised lip projecting above surfaces of the coveradjacent the raised lip; and the bearing surface of the head engages theraised lip when the fastener is inserted through the first fastener holeand into the second fastener hole to fasten the cover to the tray. 6.The battery assembly of claim 1, wherein the body of the fastenercomprises a threaded portion that engages the tray when the fastener isinserted through the first fastener hole and into the second fastenerhole to fasten the cover to the tray.
 7. The battery assembly of claim6, wherein: the body of the fastener comprises a non-threaded portiondisposed between the compression limiter and the threaded portion; and adiameter of the threaded portion is greater than a diameter of thenon-threaded portion.
 8. The battery assembly of claim 7, wherein adiameter of the compression limiter is greater than the diameter of thenon-threaded portion.
 9. The battery assembly of claim 1, wherein adiameter of the first fastener hole is greater than a diameter of thesecond fastener hole.
 10. The battery assembly of claim 1, wherein thefastener comprises a monolithic structure.
 11. A method comprising:enclosing a battery module between a cover and a tray, wherein: thecover comprises a first fastener hole; and the tray comprises a secondfastener hole, a top surface supporting the battery module, and a bottomsurface disposed on an opposite side of the tray than the top surface;and fastening the cover to the tray by inserting a fastener through thefirst fastener hole and into the second fastener hole, the fastenercomprising: a compression limiter having a length that is substantiallyequal to a thickness of the cover; and a body having a length thatextends from the top surface of the tray to the bottom surface of thetray when the fastener is inserted through the first fastener hole andinto the second fastener hole to fasten the cover to the tray.
 12. Themethod of claim 11, wherein, when the fastener is inserted through thefirst fastener hole and into the second fastener hole to fasten thecover to the tray, a bearing surface of the compression limiter abutsthe top surface of the tray.
 13. The method of claim 11, wherein: thefastener further comprises a head; and the compression limiter isdisposed immediately adjacent to the head.
 14. The method of claim 13,wherein, when the fastener is inserted through the first fastener holeand into the second fastener hole to fasten the cover to the tray, abearing surface of the head abuts a top surface of the cover.
 15. Themethod of claim 14, wherein: the cover includes a raised lip disposedadjacent an opening of the first fastener hole, the raised lipprojecting above surfaces of the cover adjacent the raised lip; and thebearing surface of the head engages the raised lip when the fastener isinserted through the first fastener hole and into the second fastenerhole to fasten the cover to the tray.
 16. The method of claim 11,wherein the body of the fastener comprises a threaded portion thatengages the tray when the fastener is inserted through the firstfastener hole and into the second fastener hole to fasten the cover tothe tray.
 17. The method of claim 16, wherein: the body of the fastenercomprises a non-threaded portion disposed between the compressionlimiter and the threaded portion; and a diameter of the threaded portionis greater than a diameter of the non-threaded portion.
 18. The methodof claim 17, wherein a diameter of the compression limiter is greaterthan the diameter of the non-threaded portion.
 19. The method of claim11, wherein a diameter of the first fastener hole is greater than adiameter of the second fastener hole.
 20. The method of claim 11,wherein the fastener comprises a monolithic structure.